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Full text of "Ford Transit MK2 gearbox+clutch"

<5orc£2 



MANUAL TRANSMISSION AND CLUTCH 



MANUAL TRANSMISSION 
AND CLUTCH 



16 



Index 


Page 


General Description 


2 


Principle of Operation 


4 


Fault Diagnosis Table 


7 


Service Checks and Adjustments 


9 


Special Service Tool Recognition 


10 


Service and Repair Operations - Content 


11 


Service and Repair Operations 


12 


Technical Data 


61 



September 1978 FORD TRANSIT '78 ONWARDS: SECTION 16-1 




MANUAL TRANSMISSION AND CLUTCH 



GENERAL DESCRIPTION 



All TRANSIT models are fitted with four-gear transmission with full synchromesh. Models are equipped with 
one of two different gearbox types. To simplify identification of these gearboxes in the Workshop Manual, 
they are given the letters 'F and 'G' respectively. 

The 'Gearbox Usage Table' given overleaf indicates which vehicles are fitted with the gearbox variants. 



'F' Gearbox 

In this gearbox the 1st/2nd gear synchroniser hub 
is pressed onto the mainshaft and forms a unit with 
it (also see Fig. 33 on page 21 ), the end float being 
controlled by selective circlips. 

In addition to the standard 'F gearbox, Fig. 1, an 
uprated version can be installed. This depends upon 
vehicle model, type and the engine fitted. 



G' Gearbox 

The 'G' gearbox, Fig. 2, is a heavy duty unit. 

Here the mainshaft ball bearing race is seated in a 
bearing block. Like the 'F gearbox, this unit has a 
bolt-on clutch housing. In both variants the clutch 
release lever and thrust bearing have to be removed 
with the clutch housing. Only then, after removing a 
spring washer, can the release lever and thrust 
bearing be detached. 

Depending on the version, the 'G' gearbox is fitted 
with one of two different extension housings (also 
see Fig. 64 on page 32). 




Fig. 1. "F gearbox 




Fig. 2. G' gearbox 



September 1978 



FORD TRANSIT '78 ONWARDS: 



SECTION 16-2 




MANUAL TRANSMISSION AND CLUTCH 



GEARBOX USAGE TABLE 



Vehicle Type 


Gearbox 


Engine 


Vehicle Version 


FT 80 


ForG 


1,6 I Kent (OHV) 
1,6 I LC(OHC) 


Van, Kombi 


FT 100 


F'orG 


1,6 I Kent (OHV) 
1,6 1 LC(OHC) 
2,0 1 LC(OHC) 
2,4 1 Diesel (OHV) 


Van 
Kombi 

Platform/chassis+single cab 
Platform/chassis+dual cab 


FT 1 00 L 


F*orG 


2,0 1 LC (OHC) 
2,4 1 Diesel (OHV) 


Van 

Kombi 

Platform/chassis+single cab 


FT 120 


F*orG 


1,6 I LC(OHC) 
2,0 I LC(OHC) 
2,4 I Diesel (OHV) 


Van 
Kombi 

Platform/chassis+single cab 
Platform/chassis+dual cab 


FT 130 


F»orG 


2,0 I LC (OHC) 
2,4 I Diesel (OHV) 


Van 
Kombi 

Platform/chassis+single cab 
Platform/chassis+dual cab 


FT 1 30 B 


G 


2,0 I LC (OHC) 


Kombi 


FT 160 


F*orG 


2,0 I LC (OHC) 
2,4 I Diesel (OHV) 


Van 

Kombi 

Platform/chassis+single cab 




F*orG 


2,0 I LC(OHC) 
2,4 I Diesel (OHV) 


Van 
Kombi 

Platform/chassis+single cab 
Platform/chassis+dual cab 


FT 190 


F*orG 


1,6 1 LC(OHC) 
2,0 1 LC(OHC) 
2,4 1 Diesel (OHV) 


Bus — 9 seater 




F*orG 


1,6 1 LC(OHC) 
2,0 1 LC (OHC) 
2,4 1 Diesel (OHV) 


Bus - 12 seater 


FT 130 


G 


2,0 1 LC (OHC) 
2,4 1 Diesel (OHV) 


Bus — 1 5 seater 



*Uprated F gearbox can be fitted as option 

NOTE: The individual gearbox variants are subject to vehicle version, type and the engine fitted. 



September 1978 



FORD TRANSIT '78 ONWARDS: 



SECTION 16-3 




MANUAL TRANSMISSION AND CLUTCH 



CLUTCH 



The clutch mechanism consists of a single-plate dry clutch with a diaphragm-spring pressure plate bolted to 
the flywheel. The clutch is operated by means of a cable (see Principle of Operation) and the release lever 
with the thrust bearing located in the clutch housing. 




Fig. 3. A -Clutch disc 

B - Pressure plate 

C - Thrust bearing with guide hub 



D - Release fever 
E - Circlip 



PRINCIPLE OF OPERATION 



Gearbox 



The engine torque is transmitted via the clutch and gearbox to the rear axle when a gear is selected. The 
matched ratios allow adaptation to varying road conditions, e.g. up or down gradients, or acceleration. 

The helically cut forward gears on the mainshaft are in constant mesh with the corresponding countershaft 
gears, with the first small gear on the input shaft engaging in the largest countershaft gear. 

The forward gears are selected with the aid of synchroniser hubs and synchroniser rings. When selecting the 
next higher gear, the higher gear on the mainshaft rotates faster than the synchroniser hub. 

After disengaging the clutch and moving the gear lever to select a gear, the selector ring of the synchroniser 
hub is pushed towards the gear selected. The selector ring pushes the synchroniser ring onto the gear cone 
with the blocker bars. 

The speed of the faster turning gear is reduced by the friction cone of the ring to that of the mainshaft, 
enabling gears to be selected. 

The reverse gear on the countershaft is straight cut and drives the 1st and 2nd sliding gear on the mainshaft 
via the engaged idler gear. 



September 1978 



FORD TRANSIT 78 ONWARDS: 



SECTION 16-4 




MANUAL TRANSMISSION AND CLUTCH 




Fiy. 4. Power (low 



September 1978 



FORD TRANSIT 78 ONWARDS: SECTION 16-5 



vvwIa 



MANUAL TRANSMISSION AND CLUTCH 



Clutch 



The friction disc connected to the gearbox input shaft lies between flywheel and pressure plate. The clutch 
disc is a steel disc with a friction lining (resilient axially) riveted on both sides. The central diaphragm spring 
presses the pressure plate against the clutch disc and the flywheel. The diaphragm spring is located between 
two fulcrum rings riveted to the clutch cover. 

When engaged, the diaphragm spring presses the pressure plate against the clutch disc so that the engine 
torque is transmitted to the gearbox. When declutching, the thrust bearing exerts a load on the centre of the 
diaphragm spring, pressing it towards the flywheel. The diaphragm spring tilts on the fulcrum ring, relieving 
the load on the pressure plate. At the same time, spring-steel straps riveted on the clutch cover lift the 
pressure plate off the clutch disc, thus disengaging engine drive. 




x =12,5- 20,0 mm 



TR16-A 



Fig. 5. Clutch mechanism 



September 1978 



FORD TRANSIT '78 ONWARDS: SECTION 16-6 



tMypcC 



MANUAL TRANSMISSION AND CLUTCH 



FAULT DIAGNOSIS - GEARBOX 



Fault 


Cause 


Remedy 


Jumping out 
of gear - 
forward gears 


Coupling teeth on gear, or selector ring 
worn or faulty. 

Axial play in mainshaft, mainshaft bearing 
or abutment face damaged or worn. 

Mainshaft nut lock-washer faulty 
(G gearbox only). 

Selector housing bolts loose. 

Mainshaft damaged or inaccurately 
machined. 

Selector ring of synchroniser hub 
sticking. 

Insufficient spring loading in gear interlock 
(ball and plunger). 

Wear in selector forks. 


Replace gear and selector ring. 

Fit new mainshaft bearing or new gearbox 
extension housing. 

NOTE: Check circlip thickness first so 
mainshaft has no axial play when fitted; see 
operation 16 118 8 -for F gearbox only. 

In G gearbox - fit new mainshaft bearing. 

Replace lock-washer, torque nut as 
specified and lock. 

Torque bolts as specified and bend washer 
tab over at 90° to inner teeth. 

Replace mainshaft complete. 

If selector ring and hub are damaged, 
replace synchroniser ring as well. 

NOTE: In F gearbox synchroniser hub and 
mainshaft for 1st and 2nd gear form a unit 
so replace mainshaft complete if necessary. 

Replace interlock springs — with balls as 
well if necessary. 

Fit new selector forks. 


Jumping out 
of gear — 
reverse gear 


Worn teeth on reverse gear idler wheel. 

Bush of reverse gear idler wheel worn or 
incorrectly inserted. 


Replace reverse gear idler wheel. 

Replace reverse gear idler wheel, changing 
spindle as well if damaged. 


Gears 
jamming 


Selector housing bolts loose. 

Selector forks not engaging completely in 
selector ring. 

Locking pins worn. 


Torque bolts as specified and lock. 

Check both parts and bring into 
engagement, fitting new parts as necessary. 
Check fork retaining pin has not dropped 
out or been damaged - if so replace. 

Fit new locking pins. 


Noises when 
selecting gear 


Synchroniser ring or synchroniser ring 
teeth worn. 

Synchroniser springs faulty or fitted 
incorrectly. 

Blocker bars worn or damaged. 


Replace both parts, changing associated 
selector ring or gear with cone as well if 
necessary. 

Fit synchroniser springs correctly or 
replace. 

Replace blocker bars. 


Stiffness 
when selecting 
gear 


See under 'Jumping out of Gear' and 'Noises when selecting gear'. 



Noises are inevitable in new gearboxes or when new gears are fitted, so a new gearbox should not 
be stripped if at all possible during running in. 

Also check before seeking faults in the gearbox itself that the fault in question is not to be found 
in the clutch. 

NOTE: The advice given here is only intended as a guide to faster fault-diagnosis. It is always 
advisable to have fault-finding carried out by someone with sufficient experience, able to diagnose 
the causes of noises quickly and accurately. 



September 1 978 



FORD TRANSIT '78 ONWARDS: 



SECTION 16-7 



Cwvrd J 



MANUAL TRANSMISSION AND CLUTCH 



FAULT DIAGNOSIS - CLUTCH 



Fault 


Cause 


Remedy 


Clutch 

slipping 


Clutch pedal play incorrectly adjusted. 


Adjust to specification. 


Linings of clutch disc smeared with 
oil or grease residues. 


Fit new oil seal to guide sleeve if leaking, 
then fit new clutch disc. 




Clutch lining worn. 


Replace clutch disc. 


— 


Contact pressure of pressure 
plato too low. 


Fit new diaphragm spring or replace 
pressure plate complete, 


Clutch has overheated. 


Replace clutch complete. 


Clutch 
snatching 


Engine or gearbox mounting faulty. 


Repair or replace as necessary.- 


Clutch lining dirty or glazed 


Clean clutch disc or replace as necessary. 


Pressure plate or release lever pressing 
on one side. 


Check diaphragm spring and if necessary 
replace pressure plate complete, 
Check release lever and thrust bearing 
function correctly when fitted. 
Replace both parts if necessary. 


Clutch disc torsion springs faulty. 


Replace clutch disc 


Clutch 
noisy 


Thrust bearing faulty. 


Replace thrust bearing. 


Torsion spring faulty. 


Replace clutch disc. 


Diaphragm spring faulty. 


Replace pressure plate complete. 


Pilot bearing or bush of gearbox input 
shaft faulty. 


Replace pilot bearing or bush. 



^flntfimhfir 1 97R 



FDRn TRAM SIT '7ft DiNllA/A RnG < 



SFtrriniu ir_h 




MANUAL TRANSMISSION AND CLUTCH 



SERVICE CHECKS AND ADJUSTMENTS 



Gearbox 

The oil level in the gearbox should only be checked 
with the vehicle standing on level ground, having 
allowed sufficient time for the oil to cool since the 
gearbox oil tends to warm up and foam when the 
vehicle has been running. When the level is correct, 
the oil comes up to the lower edge of the filler 
opening, Fig. 6. If this is not the case, top up with 
oil of the stipulated specification (see Technical 
Data). A shortage of oil in the gearbox can only 
arise if there is a leak. 




Fig. 6. Check oil level 



Clutch 

Smooth gear-changes and complete transmission 
of the engine torque to gearbox and rear axle are 
only ensured if the clutch is correctly adjusted. 

The clutch play is measured at the pedal, and is 
adjusted, where necessary, as follows, Fig. 7. 

Slacken lock nut and adjusting nut and turn 
adjusting nut until clutch pedal can be raised by 
amount 'X' then tighten lock nut and depress clutch 
pedal fully several times. Check clutch play again 
and repeat adjustment operation if necessary. 




i . 12,5 ■ 20.0 mm 



TR16-96 



Fig. 7. Clutch play adjustment 



September 1978 



FORD TRANSIT '78 ONWARDS: 



SECTION 16-9 




MANUAL TRANSMISSION AND CLUTCH 



SPECIAL SERVICE TOOL RECOGNITION 



Tool 



Tool Name 




16-003 G 



Dummy countershaft 




16-009 



Gearbox mounting bracket 




16-011 G 



Gearbox extension housing bush remover 




16-015 F 



installer for gearbox extension housing 
bush and oil sea! 




16-016 G 



Installer for gearbox extension housing 
bush and oil seal 




16-025 F 



Gearbox extension housing bush remover 




16-027 G 



Mainshaft nut wrench 




17-001 F 
G 



Gearbox extension housing oil seal remover 




21-036 B 
G 



Flywheel bearing remover 




21-044 



Clutch plate installer/aligner 



September 1978 



FORD TRANSIT 78 ONWARDS: SECTION 16-10 




MANUAL TRANSMISSION AND CLUTCH 



SPECIAL SERVICE TOOL RECOGNITION (cont'd) 



Tool 


Tool Name 


^^^^ J 21-080A 


Clutch plate locator and flywheel bearing 
replacer 



SERVICE AND REPAIR OPERATIONS - CONTENT 



Manual Transmission and Clutch 

F gearbox 'G' gearbox 



Described 



Contained 

in 
operation 



Also applicable to 
the models below 



CD 



CD 
U 



« CO 

3 C 

C +3 

3 )- 

CO O 

l-CJ 



CD 
"D 
CD 

C 

CD 

i_ 

CD 



Gearbox 

16 114 

16 118 8 

16 134 5 

16 144 4 

16 146 5 

16 154 4 

16 162 4 
16 164 

16 166 4 
16 172 

16 202 4 

16 264 8 

16 284 4 
16 524 

Clutch 



Transmission assembly - remove and 
install 

Transmission assembly - overhaul 

Pilot bearing - remove and install 

Seal - input shaft — replace 

Bearing - input shaft - replace 

Bearing - main shaft - replace 

Extension housing - remove and install 

Bush - extension housing — replace 

Seal - extension housing - replace 

Gear - speedometer driven — remove 
and install 

Synchroniser rings — replace 

Selector housing —overhaul 

Selector mechanism — remove and insta 

Gear lever - remove and install 



X 
X 
X 



1 6 724 4 Clutch disc and pressure plate - 
remove and install 

16 756 4 Linings — clutch disc — replace 

16 784 4 Clutch housing — remove and instal 

16 812 Clutch pedal — remove and install 

16 813 Bushes - clutch pedal - replace 

16 814 Cable - clutch operating - remove 

and install 



X 

X 
X 
X 

X 
X 

X 



X 
X 
X 



X 



X 



X 



X 
X 

X 
X 



16 118 8 

16 118 8 

16 118 8 

16 118 8 

16 164 

16 118 8 

16 264 8 



16 118 8 



16 812 



X 



X 



X 



X 



X 



X 
X 



X 
X 



X 
X 



X 
X 



X 



X 



X 
X 



September 1978 



FORD TRANSIT '78 ONWARDS: 



SECTION 16-11 




MANUAL TRANSMISSION AND CLUTCH 



16 114 TRANSMISSION ASSEMBLY - 
REMOVE AND INSTALL 

Special Service Tools Required: None 
To Remove 



1. 



Drive vehicle over a pit or onto ramp, open 
hood, fit wing covers. Disconnect earth 
strap from battery. 

Slacken clutch cable at pedal bracket, Fig, 8. 
Disconnect reversing lamp switch (where 
fitted) and disconnect gearbox earth strap. 
Loosen oil filler piug. 



Pull off release lever gaiter. Detach clutch 
cable from release lever, pulling cable down- 
wards by hand in front of the release lever, 
holding it with pliers and disconnecting cable 
end, Fig. 9. 




Fig. 8. Clutch cable slackened at pedal bracket 




Fig. 9. Disconnect clutch cable from release lever 



4. Remove gear lever from underneath, Fig. 10. 

5. Disconnect starter motor lead. 

6. Remove starter motor (3 bolts). 

7. Detach speedometer cable from drive. 

8. Detach clutch housing cover (2 bolts). 




Ffg. 10, Remove gear (ever from underneath 



September 1978 



FORDTRANSIT '78 ONWARDS: 



SECTION 16-12 



<Mm£ 



MANUAL TRANSMISSION AND CLUTCH 



10. 



11. 



Unbolt driveshaft from drive flange and floor 
pan centre bearing (6 bolts), Fig. 11. Draw 
shaft complete out of gearbox extension 
housing. 

To ensure no oil escapes, slide an old drive 
shaft stub or mainshaft cap into extension 
housing. 

Detach gearbox cross-member complete 
from floor pan and gearbox {5 bolts). 

NOTE: Support gearbox. 

Remove flange bolts (5) securing engine to 
gearbox. 



12. Lift out gearbox carefully. 



To Install 



13. 



14. 



15. 



16. 



Lightly grease gearbox input shaft and fit 
gearbox. 

Locate clutch housing with two opposing 
bolts done up finger tight. Then insert remain- 
ing bolts. Torque all bolts as specified. 
Fig. 12. 



Attach gearbox cross member to gearbox and 
floor pan and tighten bolts to specified 
torque, Fig. 13, 

Remove plug from extension housing and 
refit driveshaft complete. Loosely locate 
centre bearing with shims on floor pan. 
Connect driveshaft to rear axle flange and 
tighten bolts to specified torque. Then secure 
centre bearing so as to be parallel with the 
driveshaft and free of stress, tightening bolts 
to specified torque. 




Fig, 1 1 . Driveshaft mounting - rear axle flange and centre 
bearing 

A — Centre bearing 
B - Rear axle flange 




Fig. 12. Fit gearbox to engine flange 




Fig. 1 3. Gearbox cross-member secured to floor pan 



September 1978 



FORD TRANSIT "78 ONWARDS: 



SECTION 16-13 




MANUAL TRANSMISSION AND CLUTCH 



16 114 (cont'd) 

1 7. Refit clutch housing cover. 

1 8. Attach speedometer cable. 

19. Fit starter motor. 

20. Connect starter motor lead. 

21. Fit gear lever, Fig. 14. 



22. 



23. 
24. 

25. 



Attach clutch cable to release lever. To do 
this, pass clutch cable through guide in the 
clutch housing and slip on gaiter. Draw the 
cable out of its sheath, hold with pliers and 
connect to release lever. Fit gaiter in place. 
Fig. 1 5. 



Adjust clutch pedal play. Fig. 1 6. 

Check gearbox oil level and top up if 
necessary. 

Connect battery earth strap, reversing lamp 
switch (where fitted) and gearbox earth strap. 
Close hood and remove wing covers. 

NOTE: Depending on the variant, either 
the EARTH terminal only, or the EARTH 
terminal and LIVE cable support brackets 
are retained by the gearbox flange bolts. 




Fig. 14. Fit gear lever 




Fig. 1 5. Attach clutch cable to release lever 




x 12,5 20,0mm 



TR16-96 



Fig. 16. Adjusting clutch play pedal movement 



September 1978 



FORD TRANSIT '78 ONWARDS: 



SECTION 16-14 




MANUAL TRANSMISSION AND CLUTCH 



16 118 8 



F' GEARBOX 




September 1978 



FORD TRANSIT '78 ONWARDS: 



SECTION 16-15 



CV&d, 



MANUAL TRANSMISSION AND CLUTCH 



16 118 8 



T' GEARBOX 




September 1978 



FORD TRANSIT '78 ONWARDS: 



SECTION 16-16 




MANUAL TRANSMISSION AND CLUTCH 



F GEARBOX 



16 118 8 TRANSMISSION ASSEMBLY 
- OVERHAUL (Gearbox 
removed) 



Special Service Tools Required: 

Gearbox mounting bracket 16-009 
Installer for extension housing 

bush and oil seal 16-015 

Extension housing bush remover 16-025 

Extension housing oil seal remover 1 7-001 

To Dismantle 

1. Unscrew oil plugs and drain oil. 

2. Unbolt clutch housing (4 bolts). 

3. Remove clutch thrust bearing with release 
lever, Fig. 1 9. 




Fitj. 1 9. Remove thrust bearing and release lever 
A - Detach clutch housing 
B — Remove release lever 



Secure gearbox to stand with Special Tool 
No. 1 6-009 for further dismantling, Fig. 20. 



5. Detach selector housing from gearbox casing 
(7 bolts). Fig. 21. 

6. Take out selector forks for 1st/2nd and 
3rd/4th gears. 




Fig. 20. Secure gearbox to stand with Special Tool No. 16-009' 




TR16-18 



Fig. 2 1 . Selector housing removed 



September 1978 



FORD TRANSIT '78 ONWARDS: 



SECTION 16-17 



C&wnl 



MANUAL TRANSMISSION AND CLUTCH 



16 118 8 (cont'd) 



F GEARBOX 



7. Remove extension housing oil seal with 
Special Tool No. 1 7-001 , Fig. 22. 



8. Extract extension housing bush with Special 
Tool No. 16-025, Fig. 23. 

Extension housing oil seal or bush can 
only be changed when extension housing 
and mainshaft are fitted in place. 



9. Remove 4 bolts securing extension housing, 
pull extension housing out of seat in gearbox 
casing and turn until there is sufficient space 
to remove countershaft, Fig, 24. 




Fig. 22. Remove seal with Special Tool No, 1 7—001 




Fig. 23. Extract extension housing bush with Special Tool No. 
16-025 




Fig. 24. With extension housing bolts removed, turn extension 
housing until countershaft can be removed 



September 1978 



FORD TRANSIT '78 ONWARDS: 



SECTION 16-18 



C(Mwa£ 



MANUAL TRANSMISSION AND CLUTCH 



F GEARBOX 



Tap countershaft backwards out of press fit 
from front end using dummy countershaft 
(countershaft shortened to a length of 
177 mm). 

Dummy countershaft must be in con- 
stant contact with countershaft so that 
the needle rollers do not fall out of place. 



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11. Remove main drive gear bearing retainer 
(3 bolts), Fig. 26. 

NOTE: When removing bearing retainer, 
make sure oii seal is not damaged. Replace if 
necessary when reassembling. 

12. Move countershaft gears to one side, draw 
out input shaft towards the front. 



Remove extension housing with mainshaft 
assembly. Fig. 27. 

Remove countershaft gears with dummy 
countershaft and 2 thrust washers from gear- 
box casing. 



Fig. 25. Tap out countershaft 

A1 — Dummy shaft (countershaft shortened to 

177 mm) 
B2 - Countershaft 




Fig. 26. Detach main drive gear bearing retainer 




TR 16-23 



Fig. 27. Remove extension housing complete 



September 1978 



FORD TRANSIT '78 ONWARDS: 



SECTION 16-19 




MANUAL TRANSMISSION AND CLUTCH 



16 118 8 (cont'd) 



F GEARBOX 



15. Remove reverse gear idler shaft, Fig. 28. To 
do this, take a copper mandrei and drive 
reverse gear idler shaft out towards the rear, 
remove reverse gear. 

NOTE: Do not strike gearbox casing when 
removing idler shaft (risk of cracking). 




Fig. 28. Remove reverse gear idler shah 



16. Unscrew speedometer drive unit complete 
from gearbox extension housing. Then 
remove drive gear bearing, Fig. 29. 




fig. 29. Remove speedometer drive unit 



To Dismantle Mains ha ft 

1 7, Remove mainshaft bearing retaining ring 
from groove in extension housing, Fig. 30. 
Drive mainshaft out of the extension housing 
using a copper hammer. 




Fig. 30. Remove bearing retaining ring from extension housing 



September 1978 



FORDTRANSIT "78 ONWARDS: 



SECTION 16-20 



ffiwd^X 



MANUAL TRANSMISSION AND CLUTCH 



F* GEARBOX 



18. Remove circlip from 3rd/4th gear synchron- 
iser hub. Detach synchroniser hub with 3rd 
gear by hand. Fig. 31 . 



19. After removing circlip and thrust washer, 
detach 2nd gear from mainshaft, Fig. 32. 



20. Dismantle 1st/2nd gear synchroniser 
assembly. 

NOTE: 1st/2nd gear synchroniser hub and 
mainshaft are fitted together to form a unit. 
Fig. 33. 




Fig. 31. Remove circlip from 3rd/4th gear synchroniser hub 




Fig. 32. Remove circlip, pull off 2nd gear 

A -Circlip C- 2nd gear 

B - Thrust washer D - Synchroniser ring 







/=~^^^L^ 


TR 16-26 




K 



Fig. 33. Mainshaft with 1st/2nd gear synchroniser hub 



September 1978 



FORD TRANSIT '78 ONWARDS: 



SECTION 16-21 



CpwctJ 



MANUAL TRANSMISSION AND CLUTCH 



16 118 8 (cont'd) 



F GEARBOX 



2 1 . Remove mainshaft bearing circiip at the rear. 
Press off ball bearing and speedometer worm 
gear, Fig. 34. 

NOTE: To remove the bearing, locate a 
suitable U-shaped remover under 1st gear. 

22, Then detach spacer ring and extension 
housing circiip. 



23. Dismantle 3rd/4th gear synchroniser hub, 
Fig. 35. Remove selector ring, blocker bars 
and springs. 




Fig. 34. Press off mainshaft bearing 




Fig. 35. Synchroniser hub exploded 



To Reassemble Mainshaft 

24. Assemble 3rd/4th gear synchroniser hub: 
insert blocker bars and fit springs so that they 
are staggered with their opposite ends 
located in the same blocker bar, Fig. 36. 

The marks on selector ring and hub must 
coincide. 




Fig. 36. Synchroniser hub reassembled 



September 1978 



FORD TRANSIT '78 ONWARDS: 



SECTION 16-22 




MANUAL TRANSMISSION AND CLUTCH 



F GEARBOX 



Insert 1st gear synchroniser spring in hub. 
Fig. 37. To do this, first insert blocker bars 
and then fit the synchroniser springs offset 
relative to one another, starting with the 
same blocker bar. 




Fig. 37. Fit synchroniser springs 



Slide 1st gear with synchroniser ring and oil 
scoop ring onto the mainshaft. Fig. 38. 

NOTE: Large diameter oil scoop ring faces 
the ball bearing side. 




Fig, 38. Slide 1 si gear with synchroniser ring and oil scoop ring 
onto mainshaft 
A - Synchroniser ring 
B - 1 st gear 
C - Oil scoop ring 



Establish thickness of extension housing 
circlip for mainshaft bearing. When using a 
new bearing or a new extension housing, 
the thickness of the circlip must be 
established as follows: 

Locate circlip in the groove in the extension 
housing and press outwards so that it bears 
on the shoulder. Measure distance between 
bearing stop and top edge of circlip exactly 
(total height} using a depth gauge. Fig. 39. 
Measure breadth of bearing to be fitted and 
deduct bearing width from total height. Fig. 
40. This gives the circlip thickness. 




Fig. 39. Establish circlip thickness 



September 1978 



FORD TRANSIT '78 ONWARDS: 



SECTION 16-23 




MANUAL TRANSMISSION AND CLUTCH 



118 8 (cont'd) 



F' GEARBOX 



Example 



Total height 
Bearing width 

Required circlip 



17,98 mm 
1 5,92 mm 

2,06 mm 



From the available range of circlip 
thicknesses (see Parts Catalogue) choose one 
of this size and fit it loosely on the mainshaft. 
The circlip used must not have any axial 
play- 



Coat bearing seat on the mainshaft with 
multi-purpose grease, fit bearing and insert 
circlip. 

NOTE: Circlip must not have any axial play. If 
it does, select the right circlip from the range 
in the Parts Catalogue. 

Fit speedometer worm gear, Fig. 41 . 

NOTE: Distance between ball bearing and 
speedometer worm gear outer edge must be 
82,25 mm 



Reassemble 1st/2nd gear synchroniser hub: 
insert blocker bars and fit synchroniser 
springs staggered with their opposite ends in 
the same blocker bar, Fig. 42. 

NOTE: Marks on sliding gear and hub must 
coincide, with selector groove pointing to 
front. 




Fig. 40. Measure thickness of mainshaft bearing 




Fig. 41 . Location of speedometer worm gear 
A -82,25 mm 




Fig. 42. Insert synchroniser springs 



September 1978 



FORD TRANSIT '78 ONWARDS: 



SECTION 16-24 




MANUAL TRANSMISSION AND CLUTCH 



f GEARBOX 



31. Slide 2nd gear with synchroniser ring and 
thrust washer onto mainshaft, fit circlip, Fig. 
43. 

NOTE: Locate circlip correctly. 



32. Slide 3rd gear with synchroniser ring onto the 
mainshaft, Ftg. 44. 



33. Slide 3rd/4th gear synchroniser hub onto the 
mainshaft with the long side of the hub to the 
front, fit circlip, Fig. 45. 




Fig. 43. 2nd gear with thrust washer and circlip fitted 




Fig, 44. Slide 3rd gear and synchroniser ring onto mainshaft 




Fig. 45. Fir circlip to 3rd/4th gear synchroniser hub 



September 1978 



FORD TRANSIT '78 ONWARDS: SECTION 16-25 



C&ofx£ 



MANUAL TRANSMISSION AND CLUTCH 



16 118 8 (cont'd) 



F GEARBOX 



34. Warm extension housing in hot water and fit 
to mainshaft assembly. Insert previously 
loosely fitted circlip in the groove in the 
extension housing, Fig. 46. 




Fig. 46. Insert mainshaft in extension housing 



To Overhaul Input Shaft and Countershaft 
Gears 

35, Detach circlip from input shaft and press off 
input shaft bearing. Fig, 47. 



36. Coat bearing seat on input shaft with multi- 
purpose grease, press on ball bearing and fit 
circlip. 

37. Remove dummy shaft from countershaft gear 
train, Fig. 48, remove the 19 or 21 needle 
rollers with the spacer shims (2 each} on 
either side of the gear train. Remove spacer 
tube. 




Fig. 47. Press off input shaft bearing 




Fig. 48, Remove dummy shaft from countershaft gear train 



September 1978 



FORD TRANSIT '78 ONWARDS: 



SECTION 16-26 




MANUAL TRANSMISSION AND CLUTCH 



118 8 (cont'd) 



F GEARBOX 



Reassemble countershaft gear train: slide 
dummy shaft with spacer tube into gear train, 
fill space between shaft and bore with multi- 
purpose grease then introduce needle rollers 
and spacer shims, Fig. 49. 

NOTE: Long needle rollers at the rear. 




Fig. 49. Countershaft gear train dismantled 



Remove oil seal of main drive gear bearing 
retainer, Fig. 50. 

Using a suitable piece of tube, carefully insert 
new bearing retainer oil seal with the sealing 
lip facing the gearbox casing when in 
position. First coat sealing lip with multi- 
purpose grease. 




Fig. 50. Bearing retainer oil seal 



To Reassemble Gearbox 

Clean all parts thoroughly and lightly coat with 
specified gearbox oil before installing. 

Bolts which come into contact with the 
gearbox oil chamber must be coated with 
sealing compound. 

41. Fit reverse idler gear with selector groove to 
the rear. Insert shaft and tap in with copper 
hammer until about 0,2 to 0,8 mm 
countersunk, Fig. 51. First grease shaft with 
multi-purpose grease G3-7140. 




Fig. 51. Fit reverse idler gear 



September 1978 



FORD TRANSIT '78 ONWARDS: 



SECTION 16-27 




MANUAL TRANSMISSION AND CLUTCH 



16 118 8 (cont'd) 



F GEARBOX 



Stick front thrust washer of countershaft gear 
train to recess in gearbox casing with grease, 
Fig. 52. 

Place countershaft gear train with dummy 
shaft in gearbox casing and fit rear thrust 
washer. 

NOTE: Thrust washers must not be moved. 




Fig. 52. Stick thrust washers of countershaft gear train to 
gearbox casing 



Fit extension housing with mainshaft and 
then turn housing so that the countershaft 
can be installed. Fig. 53. 

NOTE: Stick extension housing gasket to 
flange using grease so as to avoid damage. 




Fig. 53. A/B - Fit extension housing and then turn so that hole 
for countershaft is accessible 



Oil needie bearing and fit to input shaft. Slide 
synchroniser ring over input shaft cone. 

Slide input shaft with ball bearing into 
gearbox casing until the circlip on the outside 
rests against the casing. Fig. 54. 




Fig. 54. Slide input shaft into casing 



September 1978 



FORD TRANSIT '78 ONWARDS: 



SECTION 16-28 




MANUAL TRANSMISSION AND CLUTCH 



47. Fit main drive gear bearing retainer with a 
new gasket, Fig. 55. 

NOTE; Fit bolts coated with sealing 
compound. Oil port must line up with hole in 
gasket and bearing retainer. 

When fitting the bearing retainer, bind input 
shaft splining (with adhesive tape or the like} 
to avoid damaging oil seai. 



Turn gearbox through 180° until countershaft 
gear train engages with main and input 
shafts. Then line up countershaft gear train 
with the holes in the casing, ensuring correct 
seating of thrust washers at the same time. 
Tap countershaft into the casing from the 
rear, keeping it in constant contact with the 
dummy shaft, and drive in flush with a copper 
hammer (on clutch housing side). Remove 
dummy shaft. 

NOTE: The flattened end of the shaft must be 
horizontal, Fig. 56. 

Then turn gearbox casing back into correct 
position. 



Line up extension housing, coat bolts (4) with 
sealing compound and insert then tighten, 
Fig, 57. 



F GEARBOX 




Fig. 55. Fit mam drive gear bearing retainer 




Fig, 56, Ftt countershaft 




Fig. 57. Extension housing lined up 



September 1978 



FORD TRANSIT '78 ONWARDS: 



SECTION 16-29 



SSZrt 



MANUAL TRANSMISSION AND CLUTCH 



16 118 8 (cont'd) 



F GEARBOX 



Fit extension housing bush with Special Tool 
No. 16-015, Fig. 58. 

The bush must be installed so that the oil 
return groove sits in the extension housing at 
the bottom and to the rear, thereby ensuring 
tnat the gap (notch) in the bush is not located 
over the oilway. 




Fig. 58. Press in extension housing bush with Special Tool No. 
16-015 



51. Coat extension housing oil seal with multi- 
purpose grease and fit seal with Special Tool 
No. 16-015, Fig. 59. 

52. Screw in speedometer drive unit complete 
(gear and bearing). First coat thread with 
sealing compound. 




Fig. 59. Fi( oil seal with Special Tool No. 1 6-01 5 



Install selector forks for 1st/2nd and 3rd/4th 
gears with the cast number facing the front. 
Fig. 60. 











TR16-A2 




®\ 


^5fc K 



Fig. 60. Fit selector forks 

A - 1 st/2nd gear fork 
B - 3rd/4th gear fork 



September 1 978 



FORD TRANSIT 78 ONWARDS: 



SECTION 16-30 




MANUAL TRANSMISSION AND CLUTCH 



F' GEARBOX 



54. Fit the selector housing with new gasket, 
Fig. 61. 

NOTE: Coat bolts with sealing compound 
before inserting. 





3— , -.-:.-T r. 




Fig. 61 . Fit selector housing 



55. Detach gearbox from stand. Fig. 62. 




Fig. 62. Detach gearbox from stand 



56. Assemble clutch thrust bearing and release 
lever and secure with circlip, Fig. 63. Then 
insert release lever in clutch housing. 

57. Attach clutch housing, coating through-bolts 
with sealing compound before insertion, then 
torque bolts as specified. 




Fig. 63. Fit clutch thrust bearing with release lever 
A Thrust hearing 
B - Release lever 
C - Circlip 



September 1978 



FORD TRANSIT '78 ONWARDS: 



SECTION 16-31 




MANUAL TRANSMISSION AND CLUTCH 



16 118 8 



G GEARBOX 




September 1978 



FORDTRANSIT '78 ONWARDS: 



SECTION 16 32 



cSca^O 



MANUAL TRANSMISSION AND CLUTCH 



16 118 8 



'G' GEARBOX 






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September 1978 



FORD TRANSIT '78 ONWARDS: 



SECTION 16-33 



<J&Fc£2 



MANUAL TRANSMISSION AND CLUTCH 



'G' GEARBOX 



16 118 8 TRANSMISSION ASSEMBLY 
-OVERHAUL 
(Gearbox removed) 



Special Service Tools Required: 

Dummy countershaft 16-003 

Gearbox mounting bracket 1 6-009 

Extension housing bush remover 1 6-01 1 
Extension housing bush and oil seal 

installer 16-016 

Mainshaft nut wrench 1 6-027 

Extension housing oil seal remover 1 7-001 



To Dismantle Gearbox 

1. Unscrew oil plug and drain oil. 

2. Detach clutch housing and thrust bearing 
with release lever (5 bolts), Fig. 66. Separate 
clutch housing, thrust bearing and release 
lever. 

3. Secure gearbox to stand with Special Tool 
No. 1 6-009 tor further dismantling, Fig. 67. 



4. Detach gearbox selector housing (8 bolts). 
Fig. 68. 




Fig. 66. Remove thrust bearing with release lever 
A — Unbolt clutch housing 
B - Remove release lever 




Fig. 67, Secure gearbox to stand with Special Tool No. 
16-009 




Fig. 68. Gearbox selector housing removed 



September 1978 



FORD TRANSIT '78 ONWARDS: 



SECTION 16-34 




MANUAL TRANSMISSION AMD CLUTCH 



G' GEARBOX 



5, Remove extension housing oil seal with 
Special Tool No. 17-001, Fig. 69. 




Fig. 69, Remove oil seal with Special Tool No. 1 7-001 



Extract extension housing bush with Special 
Tool No. 16-011, Fig. 70. 

Extension housing oil seal or bush can 
only be changed while extension housing 
and mamshaft are installed. 

Remove bolts (4) securing extension housing. 
Draw extension housing out of seat in casing 
and remove. 




Fig. 70. Extract extension housing bush with Special Tool No. 
16-011 



Drive countershaft out of press fit from front 
towards the rear using Special Tool No. 
16-003, Fig, 71. Lower countershaft gear 
train. 

Dummy countershaft 16-003 must 
remain in constant contact with the 
countershaft so that the needle rollers do 
not drop out. 




Fig. 71 . Pusli out countershaft with Special Tool No. 1 6-003 
A - Special Tool No. 16-003 
B - Countershaft 



September 1978 



FORD TRANSIT '78 ONWARDS: 



SECTION 16-35 



C Uordj 



MANUAL TRANSMISSION AND CLUTCH 



16 118 8 (cont'd) 



G" GEARBOX 



Draw extension housing with mainshaft 
complete from gearbox casing and remove 
input shaft needle roller bearing, Fig, 72, 

NOTE: Move countershaft gear train away 
slightly. 



9. Remove main drive gear bearing retainer 
(3 bolts}. Fig. 73. Then pull out input shaft. 

NOTE: When removing main drive gear 
bearing retainer, make sure oil seal is not 
damaged. Replace if necessary on 
reassembly. 



Remove reverse gear idler shaft. Screw an 
M8x60 mm (5/1 6 inx24G) bolt fitted with a 
nut, washer and socket into the idler shaft. 
Draw out shaft by tightening the nut, Fig. 74. 

Remove countershaft gear train complete 
with dummy shaft and 2 thrust washers from 
gearbox casing. 




Fig. 72. Withdraw complete extension housing 
A — Extension housing 
B - Mainshaft complete 




Fig. 73. Remove main drive gear bearing retainer 




Fig. 74. Remove reverse gear idler shaft 



September 1978 



FORD TRANSIT '78 ONWARDS: 



SECTION 16-36 



wbvct J 



MANUAL TRANSMISSION AND CLUTCH 



G' GEARBOX 



To Dismantle Mainshaft 

12. Remove circlip of 3rd/4th gear synchroniser 
hub and pull off synchroniser hub and 3rd 
gear with suitable remover, Fig. 75. 




13. Unlock mainshaft nut and remove 
Special Tool No. 1 6-027, Fig. 76. 



with 



Pull off speedometer worm gear and remove 
interlock ball. 



FJg. 75. A - Remove circlip of 3nj/4th gear synchroniser hub 
B - Remove 3rd/4th gear synchroniser hub and 3rd 
gear 




L16-B0 



Fig. 76. Remove mainshaft rut with Special Tool No. 16—027 



1 5. Remove spacer sleeve and press off ball 
bearing complete with bearing retainer, 
Fig. 77. 

1 6. Remove ball bearing from retainer. 




Fig, 77. A - Bearing with retainer and spacer sleeve 
B - Remove bearing and retainer 
a — Retainer 
b — Bearing 
c — Spacer 



September 1978 



FORD TRANSIT '78 ONWARDS: 



SECTION 16-37 



CuSrcC 



MANUAL TRANSMISSION AND CLUTCH 



16 118 8 (cont'd) 



G' GEARBOX 



17. Remove oil scoop ring and 1st gear, Fig. 78. 



18. Detach circSip of 1st/2nd gear synchroniser 
hub, Fig. 79. 

1 9. Remove synchroniser hub with 2nd gear. 



20. Dismantle synchroniser hubs, Fig, 80. 

NOTE: Check marks on hub and selector ring. 




Fig. 78- Remove oil scoop ring and 1st gear 




Fig. 79. Remove circlip of 1st/2nd gear synchroniser hub 




Fig. 80. Synchroniser hub dismantled 



September 1978 



FORD TRANSIT '78 ONWARDS: SECTION 16-38 




MANUAL TRANSMISSION AND CLUTCH 



'G' GEARBOX 



To Reassemble Mainshaft 

Clean all parts thoroughly, check them and lubricate 
lightly with specified gearbox oil before installing. 



Assemble synchroniser hubs. 

NOTE: Peripheral groove on sliding gear and 
bearing face of hub must line up one above 
the other. 

Insert blocker bars and fit synchroniser 
springs staggered with their opposite ends 
located in the same blocker bar, Fig. 81 . 

Marks on selector ring and hub must line 
up. 




Fig. 81. Fit synchroniser springs 



Fit 2nd gear with synchroniser ring. Fig. 82, 
and 1st/2nd gear synchroniser hub and 
secure with circlip. 

NOTE: Peripheral groove on sliding gear must 
point towards the rear. 



23. Fit 1st gear with synchroniser hub, Fig. 83. 




Fig. 82. Fit 2nd gear 




Fig. 83. 1st gear and synchroniser ring fitted 



September 1978 



FORD TRANSIT '78 ONWARDS: SECTION 16-39 



i/fod J 



MANUAL TRANSMISSION AND CLUTCH 



16 118 8 (cont'd) 



C GEARBOX 



24. Fit oil scoop ring with oil groove facing the 
gear, Fig. 84. 

NOTE: Make sure guide groove is located 
correctly. 



25. Insert ball bearing in retainer, 

NOTE: Coat bearing seat in retainer with 
multi-purpose grease. 




Fig. 84. Oil scoop ring with oil groove facing gear 



26. Press bearing and retainer into place using a 
suitable piece of tubing. 



27. Fit spacer sleeve, insert interlock ball and 
slide on speedometer worm gear, Fig. 85. 




Fig. 85. Fit spacer sleeve with speedometer worm gear 



28. Insert lock washer with tabs in recess in 
speedometer worm .gear. Tighten mainshaft 
nut to specified torque with Special Tool No. 
16-027 and lock, Fig. 86. 

NOTE: Bend tabs of washer for mainshaft nut 
at 90° to inner teeth. 




Fig. 86. Torque nut to specified value with Special Tool No. 
16-027 



September 1978 



FORD TRANSIT '78 ONWARDS: 



SECTION 16-40 



C (jord, A 



MAN UAL TRANSMISSION AND CLUTCH 



G' GEARBOX 



29. Fit 3rd gear with synchroniser ring and 
engage 3rd/4th gear synchroniser hub, then 
press into place using a suitable piece of tube 
and fit circiip. 

NOTE: Fit 3rd/4th gear synchroniser hub with 
the peripheral groove on the sliding gear 
facing the rear. Fig. 87. 




Fig. 87. Synchroniser hub fitted 



Overhaul Input Shaft and Countershaft Gear 
Train 



30. 



31. 



32. 



Remove circlips from input shaft and ball 
bearing, Fig. 88. Then press ball bearing off 
input shaft. 



Press ball bearing onto input shaft, Fig. 89. 
and fit circtips to bearing and input shaft. 

NOTE: Coat bearing seat with multi-purpose 
grease before fitting. 

Remove dummy shaft from countershaft gear 
train and take out in each case 22 needle 
rollers with the spacer shims (2 each} at both 
ends of the countershaft gear train. 




Fig. 88. Remove circlips 




Fig. 89. Fit input shaft bearing 



September 1978 



FORD TRANSIT '78 ONWARDS: 



SECTION 16-41 



OofcIj. 



MANUAL TRANSMISSION AND CLUTCH 



118 8 (cont'd) 



G' GEARBOX 



Reassemble countershaft gear train: insert 
dummy shaft, fit spacer shim, 22 needle 
rollers and then another spacer shim, turn 
countershaft gear train carefully and fit a 
further 22 needle rollers with a spacer shim 
on either side, Fig. 90. 




Fig. 90. Countershaft gear train with shaft, spacer shims and 
needle rollers 



34. Remove oil seal from main drive gear bearing 
retainer. 

35. Using a suitable piece of tube, carefully insert 
new oil seal into main drive gear bearing 
retainer so that the sealing lip points towards 
the gearbox casing when installed, Fig. 9 1 . 

NOTE: Coat sealing lip with multi-purpose 
grease. 




Fig. 9 1 . Main drive gear bearing retainer installed 



To Reassemble Gearbox 

Remove gearbox filler plug from casing, clean all 
parts thoroughly and lightly lubricate with the 
specified gearbox oil before assembling. 

Bolts in contact with the oil chamber of the 
gearbox must be coated with sealing 
compound when inserted. 

36. Fit reverse idler gear with selector groove 
pointing to the rear. Insert shaft and tap in 
with a copper hammer until only the flat end 
of the shaft projects. 

Rear flat end must line up on 
countershaft bore. Fig. 92. 

NOTE: Coat shaft with grease S-M1C- 
4505A. 




Fig. 92. Position of reverse gear shaft when fitted 



September 1978 



FORD TRANSIT '78 ONWARDS: 



SECTION 16-42 



<JoF<l 



MANUAL TRANSMISSION AND CLUTCH 



G' GEARBOX 



Stick countershaft gear train thrust washers 
to recess in the casing with grease, Fig. 93. 

Tabs of thrust washers must face the 
casing when fitted — large thrust washer 
at the front. 

Carefully insert countershaft gear train with 
dummy shaft 1 6 003 in casing and lower. 

NOTE: Thrust washers must not be moved 
during this operation. 



Insert input shaft with bearing into gearbox 
casing until circlsp abuts. 

Fit main drive gear bearing retainer with a 
new gasket. 

NOTE: Oil return port must line up with hofe 
in gasket and bearing retainer, Fig. 94. When 
installing bearing retainer, bind splining of 
input shaft (with adhesive tape or similar) to 
prevent damage to oil seal. Then coat the 
bolts with sealing compound and insert, 



Lubricate needle rollers and insert around 
input shaft, Slide synchroniser ring over the 
cone on the input shaft. 

Insert complete mainshaft in gearbox casing. 
Fig. 95, 

NOTE: Extension housing gasket must be 
fitted on gearbox casing before mainshaft is 
installed. 




Fig. 93. Stick thrust washers of countershaft gear train in 
casing 




Fig. 94. Line up oil return ports 




Fig. 95. Fit mainshaft 



September 1978 



FORD TRANSIT '78 ONWARDS: 



SECTION 16-43 




MANUAL TRANSMISSION AND CLUTCH 



16 118 8 (cont'd) 



'G' GEARBOX 



Turn gearbox through 180° until countershaft 
gear train meshes with mainshaft and input 
shaft. Then line up countershaft gear train 
with bores in the casing, taking care not to 
disturb the thrust washers. Push in 
countershaft from the rear of the casing, 
keeping it in constant contact with the 
dummy shaft 1 6-003, and tap in flush with a 
copper hammer. Remove dummy shaft. 

NOTE: The flat end of the shaft must point 
along the recess for the reverse gear shaft. 

Then turn gearbox casing back to original 
position. 

Line up bearing retainer hole with the guide 
pin in the extension housing, Fig. 96. 

Fit extension housing (4 bolts). 

NOTE: Coat bolts with sealing compound, 
insert and torque as specified. 




Fig. 96. Line up bearing retainer hole with guide pin 



Press in new extension housing bush with 
Special Tool No. 16-016, Fig. 97. 

The bush must be installed so that the oil 
return groove sits in the extension housing at 
the bottom and to the rear, thereby ensuring 
that the gap (notch) in the bush is not located 
over the oilway. 




Fig. 97. Fit extension housing bush with Special Tool No. 
16-016 



Fit new extension housing oil seal with 
Special Tool No. 16-016, Fig. 98. 




Fig. 98. Fit oil seal with Special Tool No. 1 6-01 6 



September 1978 



FORD TRANSIT '78 ONWARDS: 



SECTION 16-44 




MANUAL TRANSMISSION AND CLUTCH 



G' GEARBOX 



48. Fit speedometer drive gear with a new 0- 
ring, Fig. 99. 




Fig. 99. Fit speedometer drive gear 



49. Fit selector housing with selector forks and 
secure. Fig. 100. 

NOTE: Use new gasket for selector housing. 

50, Detach gearbox from stand and remove 
Special Tool No. 1 6-009. 



51. Install clutch thrust bearing and release lever 
in clutch housing. Fig. 101. 

52, Attach clutch housing to gearbox casing. 




TH15-46 



Fig. 100. Fit selector housing 



Fig. 1 01 , Fit release lever with thrust bearing 
A - Thrust bearing 
B - Release lever 
C - Circlip 




September 1978 



FORD TRANSIT 78 ONWARDS: 



SECTION 16-45 



C Sovct 2 



MANUAL TRANSMISSION AND CLUTCH 



16 134 5 PILOT BEARING -REMOVE 
AND INSTALL 
(Clutch pressure plate 
removed) 



Special Service Tools Required: 



Flywheel bearing remover 
Clutch plate locator and 
flywheel bearing 
replacer 



21-036 



21-080/21-004 



To Remove 



1 . Locate side arms of Special Tool No. 21-036 
behind the pilot bearing and withdraw the 
bearing by tightening the nut. Fig. 102. 




Fig. 1 02. Remove pilot bearing with Special Tool No. 
21-036 



To Replace 



Press new pilot bearing into crankshaft flange 
with Special Tool No. 21-044/21-080, Fig. 
103. 




Fig. 103. Fit pilot bearing with Special Tool No. 
21-044/21-080 



September 1978 



FORD TRANSIT '78 ONWARDS: 



SECTION 16-46 



Cu&FctJ 



MANUAL TRANSMISSION AND CLUTCH 



F' AND G' GEARBOX 



16 164 BUSH - EXTENSION HOUSING 
- REPLACE 



Special Service Tools Required: 

Extension housing bush 

remover 

Extension housing bush 

and oil seal installer 

Extension housing oil 

seal remover 



16-011/16-025 

16-015/16-016 

17-001 



To Remove 

1. Drive vehicle over a pit or onto a ramp and 
detach driveshaft from rear axle flange (4 
boltsr), Fig. 104. 

2. Disconnect driveshaft centre bearing (2 
bolts). Fig. 104. Draw shaft complete from 
extension housing, placing oil tray 
underneath. 



With the centre spindle wound out, screw 
tool 17-001 into oil seal until firmly held, Fig. 
105. Extract seal by screwing spindle in, 
holding tool firmly with an open-ended 
spanner. 

Remove extension housing bush with Special 
Tool No. 16-01 1/16-025, Fig. 106, 




Fig. 104. Driveshaft mountings -rear axle flange and centre 
bearing 

A - Centre bearing 
B — Rear axle ffange 




Fig. 105. Remove extension housing oil seal with Special Tool 
No. 17-001 




Fig. 106. Extract extension housing bush with Special Tool 
No. 16-011/16-025 



September 1978 



FORD TRANSIT '78 ONWARDS: 



SECTION 16-47 



<J&Fct2 



MANUAL TRANSMISSION AND CLUTCH 



16 164 (cont'd) 



F'AND'G' GEARBOX 



To Replace 



Press in new extension housing bush with 
Special Tool No. 16-015/16-016, Fig. 107. 

Bush must be installed so that the oil return 
groove sits in the extension housing at the 
bottom and to the rear, thereby ensuring that 
the gap (notch) in the' bush is not located 
over the oilway. 




Fig. 1 07. Fit extension housing bush with Special Tool No. 
16-015/16-016 



6. Fit new oil seal in extension housing using 
Special Tool No. 16-015/16-016, Fig. 108. 

7. Insert driveshaft in extension housing and 
engage with splining on gearbox mainshaft, 
taking care not to damage extension housing 
oil seal. Then attach driveshaft centre bearing 
to floor pan so that it is free of strain. 



8. Attach driveshaft to rear axle flange with 
bolts and new spring washers and torque as 
specified, Fig. 109. 



9. Torque centre bearing bolts as specified. Fig. 
109. 

10. Check gearbox oil level, top up with specified 
oil if necessary. 




Fig. 1 08. Fit oil seal with Special Tool No. 1 6-01 5/1 6-01 6 




Fig. 109. Driveshaft mountings - rear axle flange and centre 
bearing 

A - Centre bearing 
B - Rear axle flange 



September 1978 



FORD TRANSIT '78 ONWARDS: 



SECTION 16-48 




MAN UAL TRANSMISSION AND CLUTCH 



F' AND G' GEARBOX 



16 172 GEAR -SPEEDOMETER DRIVEN 
- REMOVE AND INSTALL 



Special Service Tools Required: None 

To Remove 

1 . Drive vehicle over pit or onto a ramp. 



2. Remove bolt (1) with speedometer cable 
bracket and detach cable (G gearbox), Fig. 
110. Slacken knurled nut of speedometer 
drive unit, detach cable and unscrew 
complete drive unit from extension housing (F 
gearbox), Fig. 111. 

NOTE: Catch oil. 




Fig. 110. Speedometer drive unit removed (G gearbox) 
A - Drive pmion 
8 — Drive pinion bearing 



3. Pull out speedometer drive unit (bearing and 
drive gear) IG gearbox). 



4. Detach bearing from drive gear and check for 
signs of wear or scoring. 



To Install 

5. Lubricate and slide drive gear into bearing. 
Check that it turns freely. 




Fig. 111. Speedometer drive unit removed (F gearbox) 



Replace bearing and drive gear or complete 
speedometer drive unit in extension housing. 
Then attach bolt and bracket (G gearbox). 
Screw in complete speedometer drive unit, 
coating thread with sealing compound {F 
gearbox). 

NOTE: In G gearbox replace O-ring if 
necessary. 



7. Connect speedometer cable. 



8. Check oil level in gearbox and top up with 
specified oil if necessary. Fig. 1 1 2. 




Fig. 1 12. Check oil level 



September 1978 



FORD TRANSIT '78 ONWARDS: 



SECTION 16-49 




MANUAL TRANSMISSION AND CLUTCH 



F* GEARBOX 




Fig. 113 

1 . Plug with seal or reversing lamp switch 

2. Blanking disks 

3. Interlock ball 

4. Spring 

5. 1 st/2nd gear selector fork 



6. 3rd/4th gear selector fork 

7. 1st/2nd gear selector rail 

8. 3rd/4th gear selector rail 

9. 1 st/2nd gear fork carrier 
10. 3rd/4th gear fork carrier 



1 1 . Selector detent plug 
12. ' Interlock plunger 

13. Interlock pin 

14. Fork guide rod 

1 5. Reverse gear selector fork 

1 6. Reverse gear selector rail 



16 264 8 SELECTOR HOUSING - 
OVERHAUL 
(Selector housing removed) 



Special Service Tools Required: None 

To Dismantle 

1. Remove threaded plug of selector detent. 
Take out spring and ball, Fig. 1 14. 




Fig. 1 14. Selector detent mechanism exploded 



September 1978 



FORD TRANSIT '78 ONWARDS: 



SECTION 16-50 




MANUAL TRANSMISSION AND CLUTCH 



*F* GEARBOX 



2. Detach blanking disks and threaded plug or 
reversing lamp switch from selector housing, 
Fig. 1 15. 




Fig. 1 1 5. Detach blanking disks and plug from selector housing 



3. Drive all locking pins from selector rails, Fig. 
116. 




TR 16-65 



Fig. 1 1 6, Remove locking pins 



4. Remove 1st/2nd gear selector rail and 
selector fork carrier. Fig. 1 17. 




Fig, 1 1 7, Remove 1s(/2nd gear selector rail 
A - Selector fork carrier 
B - Selector rail 



September 1978 



FORD TRANSIT '78 ONWARDS: SECTION 16-51 



(JordJ, 



MANUAL TRANSMISSION AND CLUTCH 



16 264 8 (cont'd) 



F GEARBOX 



Remove 3rd/4th gear selector rail and 
selector fork carrier, Fig. 1 1 8. 

Watch out for ball and spring. 



6. Remove plungers and take out reverse gear 
selector rail and selector fork. Fig. 1 19. 

Remove ball and detent spring. 

7. Remove selector fork guide rod. 



To Reassemble 

8. Refit selector fork guide rod, Fig. 1 20. 

9. Fit reverse gear selector rail and fork, first 
inserting spring and ball. Fig. 120, and then 
pressing down until selector rail can be slid 
in. 




Fig. 1 1 8. Remove 3rd/4th gear selector rail 
A - Selector fork carrier 
B - Selector rail 
C - Interlock pin 





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TR 16-68 






K 



Fig. 1 19. Remove reverse gear selector rail and selector fork 
A - Selector rail 
B - Selector fork carrier 
C - Interlock plungers 




Fig. 1 20. Selector fork guide rod fitted 
A — Guide rod 
B - Interlock ball 
C - Spring 



September 1978 



FORD TRANSIT '78 ONWARDS: 



SECTION 16-52 




MANUAL TRANSMISSION AND CLUTCH 



F' GEARBOX 



10. Fit 3rd/4th gear selector rail and fork carrier 
<n the manner described in sub-operation 9. 
In addition the interlock pin also has to be 
inserted in the hoie in 3rd/4th gear selector 
rail together with the interlock plunger for 
reverse and 3rd/4th gear selector rails, Fig. 
121. 

11. Fit 1st/2nd gear selector rail and fork carrier, 
insert interlock plunger between 3rd/4th gear 
and 1st/2nd gear selector rails then press in 
selector rail. 




Fig. 121. Fit 3rd/4th gear selector rait and fork carrier 



12. Secure all the selector rails and fork carriers 
with locking pins, Fig. 1 22. 

13. Fit blanking disks and threaded plug or 
reversing lamp switch in selector housing. 

NOTE: Apply sealing compound when fitting 
blanking disks. 




Fig. 122. Secure selector rails and fork carriers with locking 
pins 



14. Insert spring and ball of 1st/2nd gear selector 
rail and screw in selector detent plug. 

Always bring all selector rails to neutral 
position after installing, Fig. 123. 

NOTE: Sealing compound must be applied 
when screwing in plug. 




Fig. 123. Insert spring and ball of 1st/2nd gear selector rail 



September 1978 



FORD TRANSIT '78 ONWARDS: 



SECTION 16-53 




MANUAL TRANSMISSION AND CLUTCH 



G' GEARBOX 




Fig. 124. 

1. Interlock ball 

2. Spring 

3. 1st/2nd gear selector rail 

4. 1st/2nd gear selector fork 

5. 3rd/4th gear selector fork 



6. Interlock plunger 

7. Interlock pin 

8. 3rd/4th gear selector rail 

9. Reverse gear selector dog 

10, Reverse gear selector rail with fork 



16 264 8 SELECTOR HOUSING - 
OVERHAUL 
(Selector housing removed) 



Special Service Tools Required: None 

To Dismantle 

1. Remove locking pin from 1st/2nd gear 
selector fork and rail. Then drive rail out from 
one side and detach selector fork. Watch out 
for ball and spring. Fig. 125. 

2. Remove 3rd/4th gear selector fork and rail 
(as described in sub-operation 1). Here again 
watch out for ball, spring and interlock pin. 




Fig. 125 A - 1st/2nd gear selector fork 
B - 1si/2nd gear selector rail 
C - 3rd/4th gear selector fork 
D - 3rd/4th gear selector rail 
E — Interlock pin 



September 1978 



FORD TRANSIT '78 ONWARDS: 



SECTION 16-54 




MANUAL TRANSMISSION AND CLUTCH 



G' GEARBOX 



3. Remove reverse gear selector rail and fork. 
Fig. 126. {See sub-operation 1 for pro- 
cedure). 




Fig, 126. A - Remove reverse gear selector fork and ra?[ 
B - Reverse gear selector dog on rail 



4. Take out selector rail interlock plungers by 
turning selector housing on its side. Fig. 127. 



To Reassemble 

5. Fit reverse gear selector fork and rail. To do 
this, insert spring and ball and press down 
until selector rail can be pushed in, Fig. 128. 

NOTE: Insert selector fork so that the holes 
for the locking pin line up. Tap in locking pin. 




Fig. 127. Remove selector rail plungers [turn selector housing 
on its side) 




Fig. 1 28. Fit reverse gear selector fork and rail (fit ball and 
spring at same time) 



September 1978 



FORD TRANSIT '78 ONWARDS: 



SECTION 16-55 




MANUAL TRANSMISSION AND CLUTCH 



16 264 8 (cont'd) 



G' GEARBOX 



6. Insert interlock plunger between reverse gear 
and 3rd/4th gear selector rails. 

7. Fit 3rd/4th gear selector fork and rail. Fig. 
129. 

(Install as described in sub-operation 5, 
noting that the interlock pin also has to be 
inserted in the hole in the selector rail.) 







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K 



Fig. 1 29, Fit 3rd/4th gear selector fork and rail 



8. Insert interlock plunger between 3rd/4th gear 
and 1 st/2nd gear selector rails. Fig. 1 30. 



9. Fit 1st/2nd gear selector fork and rail. Fig. 
131. 
(Install as described in sub-operation 5.) 




Fig. 1 30. Insert interlock plunger between 3rd/4th gear and 
1 st/2nd gear selector rails 




Fig. 131. Fit 1 st/2nd gear selector fork and rail 



September 1 978 



FORD TRANSIT '78 ONWARDS: 



SECTION 16-56 



iM/FctJl 



MANUAL TRANSMISSION AND CLUTCH 



16 724 4 CLUTCH DISC AND 

PRESSURE PLATE - REMOVE 

AND INSTALL 

(Engine or gearbox removed) 



Special Service Tools Required: 



Clutch plate installer 
and aligner 



21-080/21-044 



To Remove 



1. Release clutch pressure plate from flywheel, 
slackening the 6 bolts evenly, and remove. 
Fig. 132. Detach pressure plate and clutch 
disc. 




Fig. 1 32. Remove clutch pressure plate 



To Install 

2. Locate pressure plate and clutch disc on 
flywheel with Speciai Tool 21-044/21-080, 
ensuring that fSat side of clutch disc faces the 
flywheel, Fig. 133. 

3. Secure pressure plate, tightening bolts evenfy 
corner to corner to specified torque. 

4. Remove centering tool 21-044/21-080. 




.Fig. 133. Fit pressure'plate and clutch disc using centering tool 
21-044/21-080 



16 756 4 LININGS -CLUTCH DISC - 
REPLACE 
(Clutch disc removed) 



Special Service Tools Required: None 

To Remove 

1. Detach clutch disc lining. Drill out rivet 
heads carefully so as not to damage 
clutch disc, Fig. 1 34. 



To Replace 

2. Rivet on clutch disc linings. Rivet linings 
one at a time corner to corner. Only use 
hollow flat-head rivets. 




Fig, 1 34, Drill out rivets of clutch disc linings 



September 1978 



FORD TRANSIT '78 ONWARDS: 



SECTION 16-57 




MANUAL TRANSMISSION AND CLUTCH 



16 524 GEAR LEVER -REMOVE AND 

INSTALL 



Special Service Tools Required: None 

To Remove 

1. Unscrew gear lever knob by hand. 



2. Remove cover plate (6 screws), Fig. 1 35. 



3. Remove rubber gaiter and plastic cap from 
underneath, take out gear lever assembly 
complete. Fig. 1 36. 




Fig. 1 35. A - Bottom rubber gaiter 
B - Top rubber gaiter 
C - Cover plate 




Fig. 1 36. Take out complete gear lever assembly 



To Install 

4. Insert gear lever and attach plastic cap from 
underneath. Fig. 137. 



5. Slide new rubber gaiters onto gear lever with 
the aid of glycerine. Then fold bottom rubber 
gaiter over the plastic cap. 



6, Fit cover plate with top gaiter. 



7. Screw on gear lever knob. 




Fig. 1 37. Fit gear (ever assembly 



September 1978 



FORD TRANSIT '78 ONWARDS: SECTION 16-58 




MANUAL TRANSMISSION AND CLUTCH 



16 812 CLUTCH PEDAL -REMOVE AND 
INSTALL 



Special Service Tools Required: None 



To Remove 

1 . Slacken clutch operating cable, unhook return 
spring and detach retaining clip from pedal 
shaft. Fig. 138, 



Slide pedal shaft along until clutch pedal can 
be pulled out of pedal bracket. Press retaining 
pin in clutch pedal out of the plastic yoke and 
remove. Disconnect clutch cable. Fig 139. 

Detach clutch pedal with bushes. 



3. Replace clutch pedal bushes. 



To Install 

4. Slide clutch pedal, fitted with new bushes, 
into pedal bracket, Fig. 140, and connect the 
clutch cable. Attach return spring. Then hold 
pedal in line with opening and slide pedal 
shaft back as far as stop, 

NOTE; Coat pedal shaft and bushes with 
molybdenum disulphide grease. 

5. Attach pedal shaft retaining clip. 

6. Check clutch pedal play and adjust as 
specified. 




Fig. 138, Clutch pedal shah retaining clip 



lP'6-87 




Fig. 139. Disconnect clutch cable 




r ' 




TR 16-88 




Fig. 1 40. Clutch mechanism exploded 

1. Return spring 4. Brake pedal 7 Pedal rubber 

2. Shaft 5, Retaining pin 8, Circlip 

3. Bush 6. Yoke 9. Clutch pedal 



September 1978 



FORD TRANSIT '78 ONWARDS: 



SECTION 16-59 




MANUAL TRANSMISSION AND CLUTCH 



16 814 CABLE -CLUTCH OPERATING - 
REMOVE AND INSTALL 



Special Service Tools Required: None 

To Remove 

1 . Drive vehicle over a pit or onto a ramp. 

2. Slacken clutch cable at pedal mounting, Fig. 
141. 



3. Detach clutch cable from clutch pedal by 
removing retaining pin from cable yoke. 

4. Pull out rubber gaiter on clutch release lever, 
disconnect cable from lever, Fig. 142. Detach 
gaiter. Press rubber cable seal out of 
bulkhead panel and remove clutch cable 
complete. 



To Install 

5. Insert complete clutch cable. 

6. Pass clutch cable through guide in clutch 
housing and fit rubber gaiter. Draw cable out 
of cover and connect to clutch release lever. 
Then insert rubber gaiter in clutch housing. 

7. Secure top end of clutch cable in cable yoke 
with retaining pin. 

8. Fit rubber cable seal in bulkhead panel. 
Adjust clutch play as specified, Fig. 143. 




Fig. 141. Slacken clutch cable at pedal 




Fig. 142. Disconnect clutch cable from release lever 




» 12,5 20,0mm 



TR16-96 



Fig. 143. Clutch play adjustment 



September 1978 



FORD TRANSIT 78 ONWARDS: 



SECTION 16-60 



&vvct 



MANUAL TRANSMISSION AND CLUTCH 



TECHNICAL DATA 
Gearbox 

Axial play - countershaft gear train 

Countershaft diameter 

Ratios - 1 st gear 

2nd gear 

3rd gear 

4th gear 

reverse gear 

Oil specification 

Oil capacity 



*F* gearbox 






*G* gearbox 


Standard | Uprated 




0,1 5 to 0,46 


0,1 8 to 0,53 


17,38 to 17,3673 


19,301 to 19,314 19,329 to 19,342 


3,96:1 


3,98 


1 


3,65 


1 4,41 


1 


2,28:1 


2,327 


1 


1,97 


1 2,35 


1 


1,41:1 


1,42 


1 


1,37 


1 1,51 


1 


1,00:1 


1,00 


1 


1,00 


1 1,00 


1 


4,238:1 


3,99 


1 


3,66 


1 4,67 


1 


SQM-2C9008-A 


1,45 I 


\ 1,985 1 



Clutch. 


STD 


HD 


STD 


HD 


STD 


HD 


100L 


Manufacturer 


Laycock 


Fichteal 
Sachs 


Laycock 
L.U.K. 
Fichtel 
Sachs 


Automotive 

Products 

Fichtel 

Sachs 


Automotive 

Products 

Fichtel 

Sachs 


Automotive 
Products 


Automotive 
Products 


Engine 


1,6 Ltr Kent 1,6 Ltr and 2,0 Ltr 

(OHO 


2, Ltr Diesel 


Type 






Single-plate dry clutch 






Clutch 
Size 


8f 


9" 


8i" 


9i" 


9|" 


10f 


9f 


Lining 
Material 


Ferodo 
2124F 


Porner 
11046 (UK) 
846 (EUR) 


Ferodo 
2124F 


Mintex 
H 26/1 


DON 

DSW8(UK) 

Smali+ 

Parkes 


Minex 
H26/1 


Ferodo 
2124 F 


Operated by 






Cable 








Outer 
Lining 
Diameter 


216 


228 


216 


242 


242 


267 


242 


Inner 

Lining 

Diameter 


146 


150 


153 


156 


162 


172 


156 


Clamped 
Thickness 


7,25 


9,3 


8,40 


8,40 


8,40 


8,52 


8,40 


Number of 

Torsion 

Springs 


5 


6 


6 


6 


6 


6 


6 


Diaphragm 

Spring 

Pressure 


5120 

(512) 


4880 
(488) 


4410 
(441) 


4930 
(493) 


4930 
(493) 


5780 
(578) 


4930 
(493) 



TIGHTENING TORQUES Nm (kpm) 



Clutch housing to gearbox casing . . 

Pressure plate to flywheel 

Main drive gear bearing 

retainer to gearbox casing 

Nut - gearbox mainshaft 

Extension housing to gearbox casing 
Selector housing to gearbox casing . 



'f gearbox 



Nm 

55 to 65 
1 6 to 20 

21 to 25 

45 to 49 
21 to 25 



(kpm) 

(5,5 to 6,5) 
(1,6 to 2,0) 

(2,1 to 2,5) 

(4,5 to 4,9) 
(2,1 to 2,5) 



'G' gearbox 



Nm 

55 to 65 
16 to 20 



(kpm) 

(5,50 to 6,50) 
(1,60 to 2,00) 



16,5 to 20,5 (1,65 to 2,05) 

35,0 to 41,0 (3,50 to 4,10) 

55,0 to 62,0 (5,50 to 6,20) 

16,5 to 20,5 (1,65 to 2,05) 



Transmission to cross member insulator 
Transmission cross member to body . . . 
Driveshaft bearing to support member . 
Driveshaft flange to differential 



Nm 

70 to 90 
40 to 50 
20 to 25 
60 to 65 



(kpm) 

(7,0 to 9,0) 
(4,0 to 5,0) 
(2,0 to 2,5) 
(6,0 to 6,5) 



September 1978 



FORD TRANSIT '78 ONWARDS: 



SECTION 16-61 



C <Jcm/ 2 



MANUAL TRANSMISSION AND CLUTCH 



CD J 
LTJ ^ 


Gear 


CM 


O 

CM 


CT) 


cm 
CN 


CN 


o 

CN 


Cft 


CM 
CM 


O 
CM 


CTJ 

T — 


CM 
CM 


T 

CN 


o 

£M 


en 

i — 


o 

CM 


en 


CO 


Worm 


CD 


CO 


CD 


CD 


CD 


CD 


ID 


CD 


LO 


ID 


Ifi 


in 


ID 


ID 


TT 


^J- 


<tf 


0) 
01 

> 


LO ^J- 

o ,- 

CM X 






CD 

13 




o 


C9 




(J 




ED 






iD 


CO 

(J 




m 


(J 


id ^j- 

cn «- 






□Q 




CD 






o 




CD 
C3 






CD 






m 
o 


o 


LO nj 
CO ,- 
i— X 




(S 


CO 
C3 


O 


00 










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ID 








ca 

a 






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m 










O 




CJ 




o 


cd 






a 


QQ 
CD 




en tx 


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CO 
CO 


* — 


cr> 

CO 

in 



c 
o 

'm 

i_ 

CU 

> 
CD 
O 

Ic 
cu 

> 


E 
o 

■a 

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CO 

i 

o 

S 


FT100, 120 van and kombi 9 and 

12— seater bus 

FT100, 120 ptatform/chassis+ 

single cab 

FT100, 120 platform/chassis + 

dual cab 


FT100\ 120*t van and kombi 

FT1 00L-1 90 van and kombi 

FT1 30B kombi 9 and 1 2-s bus*t; 

1 5— s bus 

FT100*, 120*t platform/chassis+ 

single cab 

FT1 00L-1 90 platform/chassis+ 

single cab 

FT100*, 120*t platform/chassiB+ 

dual cab 

FT130, 190 platform/chassis+ 

dual cab 


FT100, 120 van and kombi 

FT100L-190 van and kombi 

9 and 1 2-s bus; 1 5-s bus 

FT100, 120 platform/chassis+ 

single cab 

FT100L-190 platform/chassis+ 

single cab 

FT100, 120 platform/chassis+ 

dual cab 

FT130, 190 platform/chassis+ 

dual cab 


O 

en 
CC 


01 

X 

CO 

ip- 

C0 

a) 

cc 


X 


a 

to 






4,44 

4,44 
HD 




c 

(0 

E 


4,56 
5,14 


5,14 

4.56 


4,11 

4,44 
4,56 

5,14 


4,11 
4,44 


LL- 


4,63 
5,14 


5,14 
4,63 






CS 






4,63 
5,14 
5,83 


5,83 

4,63 
5.14 


o 

C 
CO 
V 

cd 


O 

cr 


X 


X 


XX X 


XX 


D 
h- 


X 


X 


X 




o 

CD 








X 


c 

CO 

E 


X 


X 




X 


cu 

c 

c 

LU 


1.6 Itr 

Kent 

(OHV) 


= G 


2,0 Itr 
LC 

(OHO 


2,4 itr 
Diesel 
(OHV) 



c 
o 

Q. 


c 
g 

E 

c 

(0 



CO 

E 

o 

< 

* 



CD 

c 
cd 

CD 

_c 

O) 

c 

CD 



o 

X 

o 

U 



o 

CM" 



c 
.2 

'■*-* 

u 

C 

"c 
o 

CJ 



.2 

CO 

D 

X 



cc 
o 

CD E 
*-* *- 

co c 

Cl n 



SeDtember 1 978 



FORD TRANSIT '78 ONWARDS: 



SECTION 1G-fi2 



MANUAL TRANSMISSION AND CLUTCH 



MANUAL TRANSMISSION AND CLUTCH 
(Overdrive) 



Contents 



General Description. 



Principle of Operation 



Fault finding 



Service Adjustments and Checks. 



Special Service Tools Recognition 



Service and Repair Operation Content. 



Service and Repair Operations 



Technical Data 



Wiring Diagram 



March 1981 



FORD TRANSIT '78 ONWARDS: SECTION 16B-1 



<7cwa£ 



MANUAL TRANSMISSION AND CLUTCH 



GENERAL DESCRIPTION 

As optional equipment, an overdrive unit is available on Transits fitted with the 2,0 litre petrol, 2,4 
litre diesel and 3,0 litre petrol engines from the start of 1980 model year, Fig.l. 

The overdrive unit is fitted on the rear of the manual gearbox, in place of the normal tail shaft 
housing. It contains a planetary gear train which connects the input and output shafts to one another. 
Depending on whether the planetary gear train is disengaged or engaged, the speed of the output shaft 
is changed from 1 : 1 to 0,778 : 1. 

The unit is operated electrically. A sliding switch in the gearshift lever knob switches electrical 
current on ("IN") or off ("OUT"), correspondingly a solenoid valve opens or closes the hydraulic 
circuit in the overdrive unit. 

Spring pressure or the hydraulic pressure acts on a clutch to hold the planetary gear train in place 
(1 : 1, direct drive) or to allow it to rotate freely (0,778 : 1, overdrive). 

The hydraulic pressure in the overdrive unit is produced by its own plunger type pump. In order that 
the overdrive can only be engaged in 3rd or top gear, inhibitor switches are fitted to the shift rods 
of 1st, 2nd and reverse gears of the 4-speed gearbox, which then break the electrical circuit, to 
prevent incorrect engaging of overdrive. 

The overdrive can be engaged or disengaged at any speed, but should usually only be engaged at speeds 
of over 50 km/h (30 miles/h) (driving in 3rd and top gear) as road and driving conditions permit. When 
driving at high road speeds, especially in 3rd gear, the overdrive should not be disengaged because 
this causes excessive engine revolutions. 




Fig.l. Manual gearbox with overdrive unit fitted - inset shows operating switch. 



March 1981 



FORL) TRANSIT '78 ONWARDS: SECTION 16B-3 



&OF<£ 



MANUAL TRANSMISSION AND CLUTCH 



PRINCIPLE OF OPERATION 

Power flow in the overdrive ("OUT" position), Fig.2A 

In direct drive, input and output shafts are connected with one another so that they turn together. 
The cone clutch is locked in contact to the output annulus (ring gear). The uni-directional clutch is 
meshed. 

Power flow in the overdrive ("IN" position), Fig. 2B 

As soon as the overdrive is engaged, the frictional connection (cone clutch - output annulus) is 
loosened by means of hydraulic pressure, and the cone clutch is pressed against the fixed brake ring. 
Cone clutch and sunwheel are held stationery; the planet carrier rotates with the input shaft at the 
same speed. The planet wheels roll off the sunwheel and drive the ring gear at their speed. The 
output shaft now turns at a faster speed than the input shaft, and the uni-directional clutch is over- 
run. At the same vehicle speed, the engine will run more slowly and efficiently, reducing fuel 
consumption and engine noise. 

The oil pump and control unit are part of the hydraulic system of the overdrive unit and are described 
separately. 




Fig. 2. A - POWER FLOW IN "OUT" POSITION 

1 - Input shaft 

2 - Cone clutch (sliding) 

3 - Spring pressure 

4 - Annulus and sunwheel locked 

5 - Output annulus (ring gear) 



- Output shaft 

- Uni-directional clutch 
(clamping rollers) 

- Planet carrier 

- Sunwheel 

- Hydraulic pressure 



B - POWER FLOW IN "IN" POSITION 

11 - Output annulus (ring 
gear 

12 - Planet wheel 

13 - Locked cone clutch holds 
sunwheel stationary. 



March 1981 



FORD TRANSIT '78 ONWARDS: SECTION 16B-4 




MANUAL TRANSMISSION AND CLUTCH 



PRINCIPLE OF OPERATION (cont'd) 

Hydraulic system 

The plunger- type oil pump in the overdrive is operated via a cam on the input shaft. The pump draws 
oil from the oil sump through a suction filter and delivers this oil via a non-return ball valve 
through a pressure filter to the operating pistons, solenoid valve and relief valve. 

In the relief valve, there is also an integrated spring dashpot which, by giving a progressive load 
application between the cone clutch and brake ring, ensures a smooth engagement and disengagement of 
the cone clutch under varying driving conditions. 

In direct drive, a residual hydraulic pressure of approximately 1,5 - 3,0 Bar is maintained within the 
system. When overdrive is engaged, this pressure is increased to an operating pressure of 
approximately 36 - 38,5 Bar. 

Hydraulic system with overdrive engaged , Fig. 4 

The overdrive switch (in the gearshift-lever knob) operated by the driver causes the solenoid switch 
to open the control valve. 

The hydraulic pressure moves the operating pistons forward, overcoming the spring pressure of the cone 
clutch, and the cone clutch is pressed into the conical brake ring. 

For purposes of self-lubrication, the oil then flows to the input shaft, flows through it to the rear 
bearing in the annulus and is then distributed for the purpose of lubricating the moving parts and 
planet wheels before it finally returns into the oil sump. 




Fig. 4. Hydraulic circuit with overdrive engaged. 

1 - Oil pump 4 - Input shaft 

2 - Hydraulic pressure filter 5 - Oil pump cam 

3 - Operating pistons 6 - Solenoid valve 



7 - Restrictor passage 

8 - Hydraulic control 

9 - Oil sump with suction 

filter 



March 1981 



FORD TRANSIT '78 ONWARDS: SECTION 16B-6 




MANUAL TRANSMISSION AND CLUTCHI 



PRINCIPLE OF OPERATION 

Hydraulic oil pressure system with overdrive disengaged 

After the overdrive switch is brought into the "OUT" position, the control valve is closed by the 
solenoid valve, cutting off the oil supply from the pump to the dashpot piston. 

By this means, oil is exhausted from the dashpot by way of the exhaust port, the spring in the relief 
valve is relaxed, and the valve returns to its direct drive position. Simultaneously, the springs of 
the dashpot valve move the dashpot piston until it reaches its stop. 

The operating pressure can now be progressively reduced, and the cone clutch is gently brought into 
contact with the output annul us (ring gear) by the clutch return springs. 




TR16-104 



Fig. 5. Hydraulic circuit with overdrive disengaged. 

1 - Oil pump 4 - Input shaft 

2 - Hydraulic pressure filter 5 - Oil pump cam 

3 - Operating pistons 6 - Solenoid valve 



7 - Restrictor passage 

8 - Hydraul ic control 

9 - Oil sump with suction 

filter 



March 1981 



FORD TRANSIT '78 ONWARDS: SECTION 16B-7 



€fifod 



MANUAL TRANSMISSION AND CLUTCH 



ELECTRICAL CONTROL SYSTEM , Fig. 6. 

When the control switch in the gearshift- lever knob is put into the "IN" position, the solenoid valve 
receives electrical current via the two inhibitor switches in the gearshift cover. 

The electrical circuit is broken by the inhibitor switches in 1st, 2nd and reverse gears. 

FAULT FINDING 

Disconnect the terminal of the power cable from the solenoid. Connect a test lamp between this cable 
and earth. Engage top gear, and put overdrive control switch [with ignition on) into "IN" position. 
The test lamp should now light. 

If this is not the case, trace the fault in the electrical system, e.g. at the fuse, in the wiring, 
at the solenoid or inhibitor switches. If the test lamp does not go out with 1st, 2nd or reverse gear 
engaged, the operation of the inhibitor switches must be checked. 




Fig. 6. Electrical connections in conjunction with overdrive unit. 

1 - Wiring loom 3 - Fuse box B - Operating switch 

1 - Plug and socket 4 - Fuse No. 11 6 - Solenoid 
connection 



7 - Gearshift cover 

8 - Gear inhibitor switch {2) 



March 1981 



FORD TRANSIT '78 ONWARDS: SECTION 16B-8 



(ficwtf 



MANUAL TRANSMISSION AND CLUTCH 



FAULT FINDING (cont'd) 
Overdrive does not engage 

1. Too little oil in gearbox. 

2. Fault in electrical circuit. 

3. Insufficient pump pressure as a result of bad sealing off of pump non-return valve ball (probably 
dirty valve seat). 

4. Insufficient pump pressure as a result of a blockage in the relief valve or a sticking piston. 

5. Pump does not work because of filter blockage. 

6. Damaged parts in the overdrive. 

7. Blocked restrictor passage. 

8. Faulty solenoid valve. 

Overdrive does not disengage 

Caution : If the overdrive does not disengage, be sure not to reverse the vehicle, otherwise 
extensive damage may be caused. 

1. Fault in electrical circuit. 

2. Cone clutch is sticking. 

This problem can occur with a new overdrive because the cone clutch has not yet been run in 
adequately. The clutch can usually be loosened with several blows (with a non-metallic hammer) on 
the brake ring. 

3. Damaged parts in the overdrive. 

4. Seized dashpot/rel ief valve. 

5. Restrictor passage blocked. 

6. Faulty solenoid valve. , 
Overdrive slips when engaging 

1. Too little oil in the gearbox. 

2. Insufficient pump pressure as a result of bad sealing off of the pump non- return valve ball 
(probably dirty valve seat). 

3. Insufficient pump pressure as a result of bad sealing of the relief valve. 

4. Partially blocked filters. 

5. Clutch lining worn or glazed. 

6. Faulty solenoid valve. 

Overdrive disengagement slow and/or no engine braking effect in over-run 

1. Blockage in restrictor passage. 

2. Dashpot/rel ief valve sticking. 

3. Faulty solenoid valve. 
Overdrive slips/no drive in reverse 

1. Seized dashpot/rel ief valve piston. - 

2. Restrictor valve partially blocked. - 

3. Solenoid control valve faulty. 

4. Sunwheel circlip adrift. 

5. Glazed/worn cone clutch lining. 



- High residual pressure 



March 1981 



FORD TRANSIT '78 ONWARDS: SECTION 16B-9 




MANUAL TRANSMISSION AND CLUTCH 



SERVICE ADJUSTMENTS AND CHECKS 



Lubrication 



Gearbox and overdrive unit have a common oil supply (see Technical Data). The oil level may be checked 
by means of the plug on the gearbox, fill to the bottom of the plug hole. 

The overdrive unit is equipped with pressure lubrication, whereby the oil from the relief valve flows 
through drillings to an annular channel in the front casing section, from there it flows through the 
centre drilling of the input shaft to the rear bearing in the ring gear. From here it is directed by 
an oil thrower onto a catcher disc in the planet carrier to the planet bearings via the hollow planet 
bearing pins. 

Following complete draining and refilling, the oil level must be checked again after a short trial run. 
It is essential that only prescribed oil be used for topping up or for an oil change. 

ON NO ACCOUNT SHOULD ANY ANTI-FRICTION ADDITIVES BE USED 

Since the gearbox and the overdrive have a common oil supply, scrupulous cleanliness must be maintained 
throughout all servicing operations. 

For cleaning externally or internally, use only petrol or paraffin , since otherwise damage may occur 
to oil seals and other parts of the unit. 

On no account should water be used during cleaning operations because this would also affect the 
operation of the overdrive. 



SPECIAL SERVICE TOOLS 






13-007 



15-010 A 



21-063 




16-030 




21-096 



Hydraulic test equipment 



Installation mandrel with spacer ring 



Sealing ring - rear overdrive housing 



Pressure take-off adaptor 



Extractor, sealing ring - overdrive housing 
rear 



March 1981 



FORD TRANSIT '78 ONWARDS: SECTION 16B-10 



<5o55a£ 



MANUAL TRANSMISSION AND CLUTCH 



SERVICE AND REPAIR OPERATIONS - CONTENTS 



MANUAL TRANSMISSION AND CLUTCH 


Described 

in this 
publication 


Contained in 
operation 


16 401 Overdrive assembly - check (includes 
top up oil level and pressure check) 

16 404 Overdrive assembly - remove and install 

lb 408 Seal - overdrive rear housing - 
repl ace 

33 562 Switch - overdrive control - remove 
and install 

33 563 Switch - inhibitor - overdrive - 
remove and install 

33 755 Solenoid - overdrive - remove and 
install 


X 
X 

X 
X 
X 


16 164 (see Section 16) 



SERVICE AND REPAIR OPERATIONS 



16 401 OVERDRIVE ASSEMBLY - CHECK (includes top up 
oil level and pressure check) 



SPECIAL SERVICE TOOLS REQUIRED: 

Hydraulic test equipment 
Pressure take off adaptor 



13-007 
16-030 



1. Before checking the oil pressure, check for 
current flow at the solenoid valve using a test 
lamp, with 3rd or top gear engaged. 

2. After first ensuring that the oil level is 
correct, remove the screw plug, Fig. 7, and then 
connect the hydraulic test equipment 13-007 
with the adaptor 16-030, Fig. 8. 

3. Jack up the rear of the vehicle and fit 
stands, then measure the overdrive oil 
pressure as follows: 

Run the transmission in top gear at 
approximately 40 km/h (25 miles/h) which should 
show a residual oil pressure of approximately 
1,7 Bar on the pressure gauge. When overdrive 
is engaged, the oil pressure should rise to 
approximately 36 - 38,5 Bar. With the overdrive 
disengaged, the pressure gauge should return to 
the residual oil pressure. 

If the prescribed oil pressure is not reached, 
this points to a fault in the hydraulic 
system. 

4. Refit screw plug with new sealing ring. 

5. Jack up, remove stands and lower rear of 
vehicle. Remove hydraulic test equipment 
and adaptor. 

6. Check oil level - if necessary top up with 
specified oil . 




Fig. 7. Screw plug for oil pressure check. 




Fig. 8. Measuring oil pressure. 



March 1981 



FORD TRANSIT '78 ONWARDS: SECTION 16B-11. 



CtftypcC 



MANUAL TRANSMISSION AND CLUTCH 



16 404 



16 404 OVERDRIVE ASSEMBLY - REMOVE AND INSTALL 

SPECIAL SERVICE TOOLS REQUIRED: NONE 

To Remove 

NOTE: Before removing the overdrive unit, the 
vehicle should be driven with overdrive engaged. 
Then disengage overdrive with the clutch 
depressed. This is the starting position for the 
removal of the overdrive unit. This releases the 
spline loading between planet carrier and uni- 
directional clutch which could make removal 
difficult. This measure is only possible when the 
overdrive unit can still be engaged. Otherwise it 
may be necessary to proceed as described under 
Item 8. 

1. Disconnect earth lead from the battery. 

2. Drain gearbox/overdrive oil. 

3. Separate driveshaft from overdrive flange {4 
bolts). 

4. Remove gearbox crossmember (4 bolts). Support 
gearbox with jack, disconnect crossmember from 
overdrive and body, Fig. 9, thereby 
disconnecting one side complete with holder. 

5. Disconnect speedometer cable (1 bolt). 

6. Disconnect solenoid- valve wiring. 

7. Remove nuts (8) at the front of the adaptor 
plate, Fig.lOA. 

6. Before removing the overdrive unit at the 
gearbox adaptor plate, the rear nuts (6), for 
releasing the spline loading, if necessary, 
should be loosened flush on the overdrive 
casing, Fig.lOB. 



NOTE: This is only necessary if the spline loading 
has not previously been released (see 
introduction). 




Fig. 9. Gearbox crossmember dismantled. 




Fig. 10. A - Nuts securing overdrive to adaptor 
plate 
B - Nuts securing rear overdrive casing 



First loosen overdrive from the adaptor plate 
with a non-metallic hammer, then lift complete 
overdrive unit out, Fig. 11. 



10. Remove gearbox crossmember bracket from the 
overdrive unit (4 bolts). 




Fig. 11. Gearbox with overdrive removed. 



March 1981 



FORD TRANSIT '78 ONWARDS: SECTION 16B-12 



lSSmc 



MANUAL TRANSMISSION AND CLUTCH 



16 40 4 



To Refit 

11. Refit gearbox crossmember bracket to over- 
drive. 

12, Fit overdrive with new gasket (do not use 
jointing compound), Fig. 12. First align 
splines by turning fin a clockwise direction) 
the output shaft while pressing the overdrive 
against the gearbox until the splines become 
engaged. Fit and tighten the nuts (8) 
securing the overdrive to the adaptor plate. 



NOTE: If the overdrive fails to meet the adaptor 
plate face by approximately 16 mn, this means 
that the splines of the uni-directional clutch 
have become misaligned. In this case, remove 
the overdrive unit, and re-align the splines. Fig, 12. Refitting overdrive unit. 




13, Connect solenoid wiring. 



14. Refit speedometer cable. 



15, Refit gearbox crossmember to body and 
overdrive unit, Fig. 13. 



16. Refit driveshaft to overdrive rear flange, 
(use new bolts and nuts). 



17. Fill transmission with specified oil. (See 
Technical Data}. 



18. Refit earth lead to battery. 




Fig. 13. Refitting gearbox crossmember. 



33 562 SWITCH - OVERDRIVE CONTROL - REMOVE AND 
INSTALL 

SPECIAL SERVICE TOOLS REQUIRED: NONE 

To Remove 

1, Disconnect earth lead from battery. 

2, Remove gear lever knob, Fig. 14. and disconnect 
wiring from overdrive control switch. 

3, Unscrew overdrive control switch from gear 
lever knob. 

To Install 



4. Screw overdrive control switch to gear lever 
knob. 

5. Connect wiring to overdrive control switch and 
replace gear lever knob. 

6. Refit earth lead to battery. 



''•SffiSSfe 








1" 


¥111^ 














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TR16-113 f 


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Fig. 14. Remove gear lever knob. 



March 1981 



FORD TRANSIT '78 ONWARDS: SECTION 16B-13 



SSrci 



MANUAL TRANSMISSION AMD CLUTCH 



33 563 



33 563 SWITCH - OVERDRIVE INHIBITOR - REMOVE AND 
INSTALL 

SPECIAL SERVICE TOOLS REQUIRED: NONE 



To Remove 



1. Disconnect earth lead from battery. 



2. Jack up vehicle and fit stands. 



3. Disconnect wiring connector from inhibitor 
terminal and then unscrew inhibitor switch 
from gearbox, Fig. 15. 



To Install 



4. Fit new sealing ring to inhibitor switch, 
refit inhibitor switch to gearbox. Connect 
inhibitor switch wiring. 

5. Jack up vehicle, remove stands and lower 
vehicle. 

6. Refit earth lead to battery. 



33 752 SOLENOID - OVERDRIVE - REMOVE AND INSTALL 
SPECIAL SERVICE TOOLS REQUIRED: NONE 
To Remove 

1. Disconnect earth lead from battery. 

2. Jack up vehicle and fit stands. 

3. Support gearbox and remove crossmember. 



4. Disconnect solenoid wiring and remove 
solenoid, Fig. 16. 



To Install 



5. Refit solenoid with a new sealing ring and 
connect solenoid wiring. 



6. Refit gearbox crossmenber. 



7. Check oil level - if necessary top up with 
specified oil . 



8. Jack up and remove stands, lower vehicle and 
refit earth lead to battery. 




Fig. 15. Remove inhibitor switch. 




Fig. 16. Remove solenoid. 



March 1981 



FORD TRANSIT '78 ONWARDS: SECTION 16B-14 



uor<l 



TECHNICAL DATA 



MANUAL TRANSMISSION AND CLUTC 



Manufacturer .. 

Model 

Overall transmission ratio 

Oil pressure with overdrive disengaged 

Oil pressure with overdrive engaged .. 

Oil specification 

Oil quantity (gearbox with overdrive) 

Tightening torques 

Stud - gearbox to adaptor.. 

Nut - gearbox to adaptor .. 

Stud - adaptor to overdrive housing 

Nut - adaptor to overdrive housing 

Nut - extension to overdrive housing 

Screw plug - Oil pressure test .. 

Bolt - Mounting bracket to overdrive 

Bolt - Mounting bracket to body crossinember 

Bolt - Crossmember to body bracket 



Laycock 

I 28 

0,778 : 1 

1,5 to 3,0 Bar 

36 to 38,5 Bar 

SQM-2C 9008-A 

3,1 litres 

Nm 

33 to 40 

50 to 62 
3,6 to 4,3 
7,1 to 11,4 

13 to 18,5 

13 to 21,5 

38 to 48 

70 to 90 
40,5 to 51 



kgf .m 

3,3 to 4,0 

5,0 to 6,2 

0,36 to 0,43 

0,71 to 1,14 

1,3 to 1,85 

1,3 to 2,15 

3,8 to 4,8 

7,0 to 9,0 

4,05 to 5,1 



lbf.ft 
23,1 to 28 
35 to 43,4 
2,5 to 3 
5 to 8 
9 to 13 
9 to 15 
26,6 to 33,6 
49 to 63 
28 to 36 



March 1981 



FORD TRANSIT '78 ONWARDS: SECTION 16B-15